Forming array displays

ABSTRACT

An array display may be formed of panels that include a resilient material positioned around their edges. The resilient material may be black to promote a seamless appearance. Because the material is resilient, it may facilitate the interconnection of panels to form the array, preventing damage during assembly or thereafter.

BACKGROUND

[0001] This invention relates generally to displays made up of aplurality of tiles or panels that are abutted together, each panelforming a part of an overall displayed image so that the array displaymay show a composite image made up of the images contributed by each ofthe panels.

[0002] An array display may be formed from display panels. The displaymay be emissive displays including those using organic light emittingdiodes (OLEDs). Each panel in turn may comprise an array of displaymodules comprising an emissive front part and a back part which is inelectrical contact with rows and columns of the front part and may alsocomprise integrated circuits that are part of the array display drivecircuitry.

[0003] Each module may include an array of pixels with row and columnaddress lines. Each panel may further comprise an optical integratorplate in some cases to which the emissive side of the front part isattached.

[0004] The modules may be attached to a frame by way of heat spreaders,for example. The heat spreaders may be attached to the back member andintegrated circuits by thermal attachment material such as thermalgrease or epoxy with good thermal conductivity.

[0005] It is desirable that the seams between panels and modules be asunnoticeable as possible. To the extent that the seams between panelsand modules are noticeable, the creation of a visually integrated,composite image made up of the contributions of all of the panels andmodules is diminished. Thus, it is desirable, to the greatest possibleextent, to create an array display that has a seamless appearance sothat the user is not distracted by the fact that the overall display'simage is made up of the contributions of a plurality of smaller units.

[0006] A black matrix of strips may be defined over a given module toobscure the boundaries between pixels. However, the black matrix on amodule may be ineffective to obscure the boundaries between arrays ofmodules and arrays of panels.

[0007] Thus, there is a need for ways to improve the seamless appearanceof array displays.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a top plan view of an array display in accordance withone embodiment of the present invention;

[0009]FIG. 2 is a cross-sectional view taken generally along the lines2-2 in FIG. 1 during assembly;

[0010]FIG. 3 is a partial, enlarged, cross-sectional view of theembodiment shown in FIG. 2 after assembly;

[0011]FIG. 4 is a cross-sectional view taken generally along the line2-2 in FIG. 1 during assembly in accordance with another embodiment ofthe present invention; and

[0012]FIG. 5 is a partial enlarged view of the embodiment shown in FIG.4, after assembly.

DETAILED DESCRIPTION

[0013] Referring to FIG. 1, an array display 10 may include a pluralityof panels 12 that abut along gaps 14. Each panel 12, such as the panel12C, may be made up of a plurality of modules 15. Each module 15generates a portion of the overall image displayed by a panel 12 andeach panel 12 creates a portion of the overall image displayed by thearray display 10. Thus, the resulting composite image of the display 10may be made up of the contributions to that image from the panels 12 andmodules 15.

[0014] In many applications, it may be advantageous to build largerdisplays from smaller modules and panels. For example, in oneembodiment, building unitary larger displays may involve more complexmanufacturing processes. In other cases, building unitary largerdisplays may result in greater losses because, if any portion of thelarger display is defective, the whole display may be ruined. Arraydisplays on the order of one thousand pixels are envisioned, withrelatively large pixels, on the order of one millimeter or greater.

[0015] Referring to FIG. 2, in one embodiment, the array display 10includes an optical integrator plate 16, placed over the emissive sideof each panel 12. Each plate 16 may have a black matrix (not shown inFIG. 2) formed on the rear side 18 of the plate 16 to obscure seams andgaps between adjacent pixels. In such case, a gap 14 exists betweenadjacent plates 16 (such as the plates 16 a and 16 b) and betweenunderlying adjacent panels 12 (such as the panels 12 a and 12 b). Eachmodule 15 may include front and back sections 18 and 20 respectively.

[0016] Referring to FIG. 3, a series of black matrix lines 22 may beformed on the underside of each optical integrator plate 16. In someembodiments, the black matrix lines 22 may be formed in transverse rowsand columns spaced apart by the width of each pixel. Thus, the blackmatrix lines 22 frame each pixel and serve to reduce the ability toperceive specific pixels while increasing contrast between pixels insome embodiments.

[0017] The spaces between adjacent plates 16, such as plates 16 a and 16b, may be filled with a filler material 24. The filler material 24 maybe optically transparent and may have substantially the same index ofrefraction as the optical integrator plates 16 themselves. In someembodiments, that index of refraction is from about 1.3 to 1.5.

[0018] The portion of the gap 14 between the optical integrator plates16 and the underlying modules 15 may be filled by a black material 26that may be a resilient material such as silicone or foam. The material26 may be of a color and size to closely match the black matrix lines22. Also, the material 26 may be positioned to continue the regularpattern of spacing between block matrix lines 22, in some embodiments.In addition, the shininess or light reflection characteristics of thematerial 26 may match those of the black matrix lines 22. In general,the material 26 may substantially match the optical characteristics ofthe lines 22.

[0019] The material 26 may take on an appearance very similar to that ofthe black matrix lines 22. Thus, the combination of the appearances ofthe portions 24 and 26 with the black matrix lines 22 is to create anoverall seamless appearance both between pixels and modules.

[0020] In addition, a separator 28 may be provided between adjacentmodules 15, such as the modules 15 a and 15 e. In some embodiments, theseparator 28 may be made of a resilient material that cushions anypotential impacts or jostling between adjacent modules 15 either duringassembly or during transportation. In one embodiment, the separator 28may be formed of a resilient material such as a polymer such assilicone. If the separator 28 is applied in liquid form it may beapplied with a syringe. Alternatively, expanding foam may be utilized asthe separator 28.

[0021] In one embodiment, the separator 28 and material 26 may be madeof the same material. In some embodiments, the material 26 and separator28 may be integrated. In another embodiment, a temporary separator 28may be applied to the modules 15 during transport.

[0022] In some embodiments, the optical integrator plates 16 may not beutilized, as shown in FIG. 4. In such cases, the gap 14 may be filledwith the separator 28 covered by the black material 26 a, as shown inFIG. 5. That is, the separator 28 may form the entire seam from front toback of the display 10. In still another embodiment, the gap 14 may befilled by front and back portions, the front portion formed at least inpart by the material 26 a and the back portion formed at least in partby the separator 28.

[0023] As in the previous embodiment, the material 26 a may be selectedand configured to closely match the appearance of the black matrix lines22. Again, the optical characteristics, as well as the spacing betweenthe material 26 a and adjacent black matrix lines 22, is such as to makethe gap 14 not readily visible. Moreover, the size of the material 26 amay be selected to substantially match that of adjacent black matrixlines 22. Thus, a relatively seamless appearance can be achieved throughthe construction of the material placed in the gap 14.

[0024] Similarly, the material 28 beneath the material 26 a may be aresilient material as described previously to prevent jostling betweenadjacent modules 15, such as the modules 15 a and 15 e.

[0025] In some embodiments, the material 26 a may be integrated with thematerial 28. Thus, the same material may be used as the material 26 aand the separator 28.

[0026] In some embodiments, a thermal attachment material (not shown)and heat spreader (not shown) may be attached to the rear of the panels12. In addition, a driver integrated circuit (not shown) may be attachedbetween the panels 12 and the heat spreader. Electrical interconnectsmay be made by appropriate connectors or mounting frames in someembodiments.

[0027] While the present invention has been described with respect to alimited number of embodiments, those skilled in the art will appreciatenumerous modifications and variations therefrom. It is intended that theappended claims cover all such modifications and variations as fallwithin the true spirit and scope of this present invention.

What is claimed is:
 1. An array display comprising: a plurality ofpanels abutted together in side-by-side arrangement to form an array anddefining seams between adjacent panels; and a resilient material aroundthe panels, the resilient material of adjacent panels abutting to formthe seam.
 2. The display of claim 1 wherein said resilient material is afoam.
 3. The display of claim 1 wherein said resilient material is apolymer.
 4. The display of claim 1 wherein said resilient material isblack.
 5. The display of claim 1 including optical integrator platespositioned over said panels, a filler material positioned between saidplates.
 6. The display of claim 5 wherein said filler material matchesthe optical characteristics of said optical integrator plates.
 7. Thedisplay of claim 5 wherein said resilient material is positioned beneathsaid filler material, said resilient material including an upperportion, said integrator plates including black matrix lines, said upperportion arranged to substantially match the optical characteristics ofsaid black matrix lines.
 8. The display of claim 7 wherein said upperportion is positioned between said optical integrator plates and saidpanels.
 9. The display of claim 1 including black matrix lines formed onthe upper surface of said panels, said material including an upperportion that substantially matches the appearance of said black matrixlines.
 10. The display of claim 9 wherein said upper portion is made ofa material that is different from said resilient material.
 11. A methodcomprising: abutting a plurality of panels together in side-by-sidearrangement to form an array display; defining seams between adjacentpanels; locating a resilient material around the periphery of eachpanel; and abutting the resilient material of adjacent panels to form aseam.
 12. The method of claim 11 including forming the seam of aresilient foam material.
 13. The method of claim 11 including formingthe seam of resilient silicone material.
 14. The method of claim 11including using a black material to form said seam.
 15. The method ofclaim 11 including positioning optical integrator plates over saidpanels and filling the region between said optical integrator plates andsaid panels with a filler material.
 16. The method of claim 15 includingmatching the optical characteristics of said optical integrator platewith said filler material.
 17. The method of claim 15 includingproviding a first seam material between said optical integrator plates,said first seam material being substantially transparent and matchingthe optical characteristics of said optical integrator plates.
 18. Themethod of claim 17 including providing a second seam material beneathsaid first seam material to match the appearance of black matrix lineson said optical integrator plates.
 19. The method of claim 18 includingproviding a third seam material below said second seam material andbetween said panels, said third seam material being resilient.
 20. Themethod of claim 11 including providing black lines over said resilientmaterial and said panels, a black line over said resilient materialoptically matching the black lines over said panels.
 21. An arraydisplay comprising: a plurality of organic light emitting device displaypanels abutted together in side-by-side arrangement to form an array anddefining seams between adjacent panels; a resilient material around eachof said panels, the resilient material of adjacent panels abutting toform the seams; and a plurality of optical integrator plates positionedover said panels.
 22. The display of claim 17 wherein a filler materialis positioned between said panels and said optical integrator plate. 23.The display of claim 17 wherein said filler material matches the opticalcharacteristics of said optical integrator plates.
 24. The display ofclaim 17 wherein said resilient material is a foam.
 25. The display ofclaim 17 wherein said resilient material is a polymer.
 26. The displayof claim 17 wherein said resilient material is black.
 27. The display ofclaim 21 wherein said resilient material includes an upper portion, saidintegrator plates including black matrix lines, said upper portionarranged to substantially match the optical characteristics of saidblack matrix lines.
 28. The display of claim 27 wherein said upperportion is positioned between said optical integrator plates and saidpanels.
 29. The display of claim 21 including black matrix lines formedon the upper surface of said panels, said material including an upperportion that substantially matches the appearance of said black matrixlines.
 30. The display of claim 29 wherein said upper portion is made ofa material that is different from said resilient material.